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DMG MORI Cooperative Complete Machining For Any Eventuality

DMG MORI is extending its range of products in the Turn & Mill area with the new NTX 1000 2nd Generation for the complete machining of small precision components

Complete machining in a single set-up has long since been a fashionable topic in production engineering. This is where DMG MORI stands out as a cooperative full-liner with a comprehensive product range, also in the machining of rotation-symmetrical components: starting with "normal" multi-axis lathes with driven tools to top class turning-milling machining centres with a B-axis and possibly an additional turret for up to 5-axis (with counter-spindle) or even 6-axis finished machining. With the new NTX 1000 2nd Generation, DMG MORI has recently extended its portfolio for high-precision Turn & Mill complete machining of smaller workpieces, and is demonstrating how completely the product ranges of the two cooperation partners now complement each other in strategic interaction with the CTX beta 800 TC.

The CTX beta 800 TC was added to the successful CTX TC series in 2014,
followed by the CTX beta 1250 TC in the 2nd Generation since February 2015.

"With the NTX 1000 2nd Generation and the CTX beta 800 TC, we can offer our customers a bandwidth for Turn & Mill complete machining of smaller components, the like of which does not exist anywhere else in the world!" For GILDEMEISTER managing director Harry Junger there can hardly be anything better – any customer requirement can be satisfied in this way. However, if the target group and the targeted workpiece range are almost identical for both machines, clear differentiation is required, which Harry Junger has at the ready (of course): "As soon as a B-axis is introduced into the multi-axis machine, in principle any component of the relevant size can be machined with any complexity whatsoever. However, the following also applies: Customers do not demand the 100 percent solution with regard to the possibilities, but only concentrate on the profitability of the process!" And against this background the new NTX 1000 2nd Generation with turning-milling spindle and bottom turret as a second tool carrier now differs decisively from the CTX beta 800 TC, which only has a turning-milling spindle, emphasises Harry Junger, adding immediately that both machines can be upgraded to a 6-side complete machining centre with an (optional) counter-spindle.

From a market strategy point of view: Thanks to the possibility of 5-axis machining, the CTX beta 800 TC closes the gap to the classical universal lathes as far as the high-performance area in the direction of maximum flexibility for chuck components, such as in mechanical engineering or in the fluid or hydraulics industry. One highlight in this respect is the new (patented) compactMASTER turning-milling spindle with Capto C6 or HSK- A63 interface as the basis for even heavy machining operations with up to 12,000 rpm in the standard and torque of up to 120 Nm (with a size of just 350 mm).

On the other hand, your customers may prefer the NTX 1000 2nd Generation for bar machining and also the series production of small, (highly) complex components in the tooling, medical engineering and aerospace areas, the watchmaking industry and the electronics area. The turning-milling spindle with Capto C5 (HSK-A50) and speeds of up to 20,000 rpm is ideal for this range of workpieces. Furthermore, the bottom BMT® turret as a second tool carrier with its direct-driven tools makes it possible to use a large number of productivity-increasing options such as 4-axis machining or parallel machining at the main and counter spindle. Particularly the shorter part times due to parallel machining with two tool carriers predestines the NXT 1000 2nd Generation for turnkey solutions in series production. This also applies to other the usage options of the second tool carrier. For example, the turret can be equipped with a rotating centring tip, which can be used to support long workpieces during machining.

Both the NTX 1000 2nd Generation and the CTX beta 800 TC appear in the new DMG MORI Design with ERGOline® Control and CELOS® for the quickest route from idea to finished product. At the control side, DMG MORI focusses on Operate 4.5 with SIEMENS 840D solutionline. The NTX 1000 2nd Generation is also alternatively available with FANUC 31iB.

The NTX 1000 2nd Generation presents itself as a compact Turn & Mill machining centre for complex turning and milling operations of middle and large quantities. In spite of having the smallest footprint in its class, the new machining centre has a surprisingly large working area. The maximum turning diameter at the workpiece spindle side is 430 mm, with a swing of 680 mm. The turning length is specified as 800 mm, with tool spindle travel distances of
455 x ±105 x 800 mm (in the X, Y and Z direction). Harry Junger particularly regards the Z-axis distance, which has been increased to 800 mm, and the 210 mm long Y-axis for off-centre machining as "decisive differentiation features in the competition between the compact Turn & Mill machining centres".

There is also the powerful B-axis with a swivelling range of ±120° as the basis for complex 5-axis simultaneous machining. The milling spindle with Capto C5 or HSK-A50 interface provides speeds of up to 12,000 rpm in the standard (optionally 20,000) whereby the tools are supplied via a chain magazine. In combination with the (optional) bottom 10-way turret and its directly driven tools (10,000 rpm), both 4-axis machining and productive parallel machining are possible at the main spindle and the counter spindle.

In spite of having the smallest footprint in its market environment, the NTX 1000 2nd Generation
has a large working area for high productive machining with B-axis and additional bottom turret.

As well as the compactness and large working areas that have been mentioned, the NTX 1000 2nd Generation has many other design highlights. These include the integration of unique original technologies such as DDM® (direct drive in the B-axis) and BMT® (high-end turret with integrated direct drive of the tools for unique milling performance). "The new development also has a comprehensive package of measures for preventing the temperature from influencing the accuracy of the machining", adds Harry Junger. The cooling of the ball-thread drive (including nuts) and the cutting and milling spindles of the B-axis and the BMT® turret are particularly worth mentioning.

In order to be able to fulfil all customer requirements in a customised way, the NTX 1000 2nd Generation is also available on the basis of a comprehensive
high-tech construction kit with different configuration levels. Here, the diversity of variants ranges from the chucker with turning-milling spindle to a version with additional tailstock/sleeve combination to the development stage with counter-spindle and additional bottom turret. In accordance with its series production characteristics, it is also possible to machine from the bar with the
NTX 1000 2nd Generation, which has a bar capacity of 52 mm or 65 mm (optional). The portfolio also includes various automation options such as gantry loaders or component handling using robots.

Harry Junger sums it up in a nutshell: "In view of all of the options, the
NTX 1000 2nd Generation is the optimum machining solution in the series production area for geometrically demanding workpieces with maximum precision." And this in turn makes this new development the undisputed "best in class" manufacturing tool in medical engineering, aerospace, the watchmaking industry and the electronics industry.

DMG MORI has expanded the successful CTX TC series with the new
CTX beta 800 TC. Its automatic tool changer provides maximum flexibility in classical turning operations involving workpieces up to Ø 500 x 800 mm. As far as Harry Junger is concerned, the highlight of the CTX beta 800 TC is the turning-milling spindle: "The Y stroke of 200 mm and the new compactMASTER ultra-compact turning-milling spindle open up a wide range of applications to users of the Turn & Mill complete machining to the extent of 5-axis simultaneous machining". The compact design of this spindle with integrated release cylinder for the tool clamp makes it possible to have torque of 120 Nm with an impressive length of just 350 mm. In comparison with a conventional spindle the increase in work area is 170 mm, with 20 percent more torque at the same time. The B-axis is also equipped with a direct drive, which makes highly dynamic machining possible with a swivel range of ±110° and rapid traverse speeds of 70 rpm.

For complex milling operations right through to 5-axis simultaneous machining, the new HSK-A63 (optionally Capto C6) compactMASTER turning-milling spindle has performance data of 12,000 rpm, 120 Nm and 22 kW. A 20,000 rpm high-speed version is also available as an option. Harry Junger states the following with regard to the different expansion options: “Our high-tech modular building block system allows customers to equip the machine individually in line with their particular range of components. Among other things, this includes different tool magazines with a capacity of up to 80 pockets rather than the 24 in the standard.

In the standard version the machine has a main spindle, designed as a liquid-cooled integral spindle motor (ISM76) with 380 Nm and 34 kW or optionally as ISM102 with 770 Nm and 38 kW, and an NC-controlled tailstock. The machine can also be equipped with a counter-spindle instead of the tailstock for 6-sided complete machining. The ISM52 PLUS with 6000 rpm and 170 Nm is provided for this purpose. Chucks up to 400 mm diameter can be used on the machine in conjunction with the ISM102 spindle motor. "Steady rests, that are available for workpiece diameters of up to 200 mm, are recommended for the machining of long workpieces" adds Harry Junger.

The sturdy travelling column design stems from the larger CTX beta 1250 TC and has long since demonstrated its quality. Maximum stability and accuracy are achieved by means of combining with the direct measuring systems in all axes of the travelling column. The machine concept also has impressive ergonomics: Whereas the CTX beta 800 TC has a large work area, its advantages with regard to accessibility and space requirement are also remarkable. The 350 mm distance from the front of the machine to the centre of the spindle is the ideal prerequisite for easy loading and unloading. The footprint is just 8.5 m² or 10.7 m² including chip conveyor.

The potential uses and target groups for the new CTX beta 800 TC are manifold. The machine is mainly intended to appeal to the classical user of a universal lathe, which is much more flexible because of the integral tool changer, since there is no need for time-consuming retooling on the turret with up to 80 tools. Furthermore, thanks to the B-axis, only low-cost standard tools are required for machining at an angle. The machine has a stroke of ±100 mm in the Y-direction, a facility which is not available on any universal lathe in this size category. Possible applications of the CTX beta 800 TC are rounded off by 11 exclusive technology cycles that are optionally available. Using these, up to 60 percent programming time can be achieved by means of extremely simple programming.

The possibilities with the versatile machine model series never cease to fascinate Harry Junger: "Our customers manufacture extremely sophisticated components with the Turn & Mill machining centres in the CTX TC series. Many workpieces show hardly any signs of having been machined on a lathe. Particularly when 5-axis simultaneous machining of free-form surfaces comes into play.”